PEP SET Technolgy. Ecofriendly - PU NB Binder System. PEP SET Silver PEP SET Blue

Transcription

1 Technolgy Ecofriendly - PU NB Binder System Silver Blue

2 50 years ago Ashland invented the Polyurethane Binder Technology

3 TECHNOLOGY

4 BINDER COMPONENTS - CHEMICAL REACTION R R' OH + OCN R" LIQUID AMINE CATALYST R R' O H O C N R" PART I + PART II PART III Catalyst Liquid Phenolic Resin + Liquid Isocyanate Resin Liquid Catalyst Solid Urethane Plastic 4 07/09/2016 Antoni Gieniec - Technical Product Management No-Bake Binders

5 PROCESS - EQUIPMENT Sand Mixing Patterns Pumping Rollover Draw Compaction Table 5 07/09/2016 Antoni Gieniec - Technical Product Management No-Bake Binders

6 PRODUCTIVITY BENEFITS WORK TIME STRIP TIME CHART Ultrasonic test STRIP TIME Receiver WORK TIME: The time period after the mixed sand leaves the mixer up until it starts to develop body. The curing reaction remains latent during work time. Chemical bonds begin to form after the sand begins to develop body. All worker related activities (filling, tucking, ramming, rebar, hooks, etc.) should occur during work time. 400 WORK TIME time [min] Thermosensoren Ultrasonic Heads STRIP TIME: The time period after the sand begins to develop body up until the mold or core is sufficiently cured such that it can be removed from the pattern. The rapid curing reaction takes place during strip time. 95% of the chemical bonds have been formed at strip time. The mold or core still remains slightly pliable / flexible at the end of strip time and can be easily removed from the pattern. 6 07/09/2016 Antoni Gieniec - Technical Product Management No-Bake Binders Measurement chamber

7 PRODUCTIVITY BENEFITS ADJUSTMENT DER REACTIVITY Time [t/min.] 30 Work Time Strip Time ,50% 1,00% 2,00% 4,00% 6,00% Catalyst Level 1. Simple adjustment in catalyst levels changes speed a) Account for sand temperature, mold size, etc. 2. Slope is not always linear a) Dependent on speed of cure, catalyst type, etc. 7 07/09/2016 Antoni Gieniec - Technical Product Management No-Bake Binders

8 PRODUCTIVITY BENEFITS RATIO PART1 - PART 2 [N/cm²] 250 Excess Part 1 Excess Part Work Time (min) Strip Time (min ) 2h 3h 24h 1. Ratio Part 1 to Part 2 can impact core & mold properties a) Strength b) Plasticity 8 07/09/2016 Antoni Gieniec - Technical Product Management No-Bake Binders

9 CASTING BENEFITS SULFUR ELIMINATION 1. Acid Cured 1.00% Binder Level a) 30% of a Typical 65% TSA Catalyst b) % Mold / Metal Interface c) Much More with Reclaimed Sand 2. = 0% Sulfur 9 07/09/2016 Antoni Gieniec - Technical Product Management No-Bake Binders

10 CASTING BENEFITS CASTING SURFACE Furan resin binder 10 07/09/2016 Antoni Gieniec - Technical Product Management No-Bake Binders

11 SHORT SUMMARY 1. Good casting surface 2. Good shake-out properties 3. High strength 4. Very good flow ability of the mixed sand 5. Curing speed is largely unaffected by temperature 6. Use of mechanically reclaimed sand possible 7. Compatible with other processes 11 07/09/2016 Antoni Gieniec - Technical Product Management No-Bake Binders

12 PORTFOLIO

13 PRODUCTIVITY BENEFITS PORTFOLIO Standard QUANTUM 5000 Series Light Metal Shakeout Strength Silver Blue Shakeout Flowability 13 07/09/2016 Antoni Gieniec - Technical Product Management No-Bake Binders

14 BENEFITS Pep Set Standard Good casting surface Good shake-out properties High strength Very good flow ability of the mixed sand Curing speed is largely unaffected by temperature Use of mechanically reclaimed sand possible Compatible with other processes Pep Set Quantum (additional) Low Emissions (odor and smoke) 14 07/09/2016 Antoni Gieniec - Technical Product Management No-Bake Binders

15 QUANTUM LOW SMOKE & ODOR QUANTUM Developed by ASK Chemicals. Quantum Competitive product 15 07/09/2016 Antoni Gieniec - Technical Product Management No-Bake Binders

16 SILVER ENVIROMENT-FRIENDLY BINDER 16 07/09/2016 Antoni Gieniec - Technical Product Management No-Bake Binders

17 THE USUAL COMPONENTS OF A FORMULATION SILVER Standard binder SILVER Ingredients: Base: Formaldehyde-Phenol-Resin / MDI Solvents with low EHS impact Aromatic Solvents Additives Monomers (phenol/formaldehyde) DANGER PICTOGRAMS Part 1: Part 2: Ingredients: Base: Formaldehyde-Phenol-Resin / MDI Solvents with low EHS impact Aromatic Solvents Additives DANGER PICTOGRAMS Part 1: Part 2: 17 07/09/2016 Antoni Gieniec - Technical Product Management No-Bake Binders

18 Phenol Concentration [mg/kg] SILVER SILVER PHENOL CONTENT IN RECLAIMED SAND STANDARD SILVER 18 07/09/2016 Antoni Gieniec - Technical Product Management No-Bake Binders

19 SILVER SILVER ADVANTAGES AT GLANCE Benefits Significant reduction of smoke Reduction of hazardous air pollution Reduction of free phenol in reclaimed sand Improved community relations and worker environment Features Low odor / low smoke / low free phenol system Reduced of phenol level pollution Fast strip time and good through-cure Good strength on new and mechanically reclaimed sand Application Aluminum, iron and steel casting High productivity / high productivity PU NB SYSTEM Small and medium castings 19 07/09/2016 Antoni Gieniec - Technical Product Management No-Bake Binders

20 BLUE LOW EMISSION BINDER 20 07/09/2016 Antoni Gieniec - Technical Product Management No-Bake Binders

21 THE USUAL COMPONENTS OF A FORMULATION BLUE Standard binder Blue Ingredients: Base: Formaldehyde-Phenol-Resin / MDI Solvents with low EHS impact Aromatic Solvents Additives Monomers (phenol/formaldehyde) DANGER PICTOGRAMS Part 1: Ingredients: Base: Formaldehyde-Phenol-Resin / MDI Solvents with low EHS impact Additives DANGER PICTOGRAMS Part 1: NO PICTOGRAMS Part 2: Part 2: 21 07/09/2016 Antoni Gieniec - Technical Product Management No-Bake Binders

22 EVAPORATION OF VOLATILE COMPOUNDS TYPICAL FORMULATIONS VOCs Monomers (Phenol / Formaldehyde) Aromatic System* SILVER* BLUE *) Formulation; contains 30% of aromatic solvent (part 1/part 2) 22 07/09/2016 Antoni Gieniec - Technical Product Management No-Bake Binders

23 SILVER BLUE ADVANTAGES AT GLANCE Benefits Reduction of hazardous air pollution as BTX Reduction of free phenol in reclaimed sand Improved community relations and worker environment Features Low odor / low free phenol / low Formaldehyde / free aromatic system Reduced level of pollution Good strength Application Aluminum, iron and steel casting Small and medium castings 23 07/09/2016 Antoni Gieniec - Technical Product Management No-Bake Binders

24 ECOFRIENDLY TECHNOLOGY QUANTUM Part 1: Part 1: Part 1: NO pictograms Advantages : Free Phenol <5% Free Formaldehyde <0,1% Low Smoke/low smell High sand performances Drawbacks : Labelling similar to serial Advantages : Free Phenol <1% Free Formaldehyde <0,1% No Heath Hazard labelling Low Smoke/low smell High sand performances Possible Drawbacks : VOC s (aromatics) Advantages : Free Phenol <1% Free Formaldehyde <0,1% No Labelling Part 1 Low smell Possible Drawbacks : Smoke 24 07/09/2016 Antoni Gieniec - Technical Product Management No-Bake Binders

25 THANK YOU! ASK Chemicals ASK